Water purifier having a demister

ABSTRACT

A distiller for producing potable water employs a metal boiler tray having a cover member in which there is an inlet for raw water and which together form a steam chamber having an outlet for steam. The boiler tray bottom has a plurality of steps including a highest, an intermediate and a lowest level step which are all covered with water at the beginning of a distillation cycle. The temperature of the highest level step is monitored with a sensor. A rise in the temperature of the highest level step by a predetermined amount above the boiling temperature of water indicates that the highest and intermediate level steps have become dry. This results in a signal to a controller to open a valve and admit replenishment raw water whose amount is dependent on valve open time. Steam evolved from the boiler tray is conducted through a first check valve in the cover member to demister chamber when the mist or carryover water in the steam impinges on a baffle and is separated from the steam as condensate. A feedback tube having a check valve interconnects the demister chamber with the steam chamber so that negative pressure in the steam chamber that accompanies infeed of cool raw water causes the condensate to be withdrawn from the demister chamber and returned to the boiler chamber.

This is a continuation of copending application Ser. No. 08/120,152filed on Sep. 10, 1993, now abandoned.

BACKGROUND OF THE INVENTION

The invention disclosed herein pertains to distillers for producingpotable water from impure water.

Typical distillers used in residences for water purification comprise aboiler to which impure (raw) water is admitted from the water mains forbeing converted to steam. The heat for effecting conversion of raw waterto steam is usually an electric heater element which, in some designs,is immersed in water within the boiler and in other designs is arrangedin heat exchange contact with an external surface of the boiler. Thegenerated steam is conducted from the boiler to the inlet of a steamcondenser which is usually cooled externally by an air stream from afan. Typically, the pure condensate is delivered to a storage tank. Amotor-driven pump is usually present in the distiller assembly fordelivering water from storage to a faucet on demand.

Residential water distillers can be technically quite sophisticated asis demonstrated in U.S. Pat. Nos. 5,110,419; 5,188,710; and 5,200,039which are assigned to the assignee of this application and areincorporated herein by reference. The distillers described in thesepatents are adapted to perform a variety of control functions of whichthe owner does not have to be aware. An electronic controller, which maybe based on a microprocessor, governs the functions. For example, asensor such as a float switch signals the controller when the quantityof pure water in the storage tank is low, in which case the controllerresponds by switching the heater element on and, possibly, at the sametime opens a raw water infeed valve and adds water to the boiler forbeing converted to steam. A sensor may detect the temperature of theheater element as a representation of the depth of water in the boilerso as to independently close the infeed valve or open it as required torepeat a steam production cycle. Data representative of the total runtime of the distiller may be accumulated in an electronic memory whichprovides a signal to the distiller owner that certain maintenance stepsmust be taken such as removal of mineral deposits from theboiler-evaporator and/or the heater element.

Generally, existing distillers perform their functions in apre-determined order. At start up, the heater element may be energizedfor a short time interval to bring the element or boiler up to nearsteam generating temperature. Next, raw water that is to be distilledand purified, is admitted to the boiler and, in a short time, generationof steam starts. Continuing evaporation of the water in the boilerresults in a drop in the water level. The low level water condition issensed and the response to the condition must be replenishment of rawwater in the boiler.

A problem in pre-existing distillers is that precise correlation betweenboiler or heater element temperature and a demand for water infeedcannot be obtained. One of the reasons is that as long as there is somewater in contact with the boiler body or with the heater element, thebody or element tends to remain at the 212° F. or 100° C. of the boilingwater. Hence, there is no sensible increase in the temperature of theheater element nor in the steam boiler body above the boilingtemperature of water until the boiler or heater element becomes totallydry. Sensing of a temperature above the boiling point of water as anindication of the boiler having gone dry induces a controller to respondby opening a raw water infeed valve. The consequences are unfavorable.The first incoming quantity of raw water runs onto a surface that issignificantly hotter than the minimum temperature that is necessary togenerate steam. This results in the raw water flashing into steam withexplosive force accompanied by a substantial increase in the steampressure within the boiler. The pressure rise can be so rapid that thesteam cannot be relieved fast enough to the condenser to avoid damage tothe boiler and even to other parts of the distiller within the distillerhousing. This problem and other problems in existing water distillersare eliminated by the invention disclosed herein. Whenever water boilsvigorously, as it often does in the small boilers used in residentialdistillers, tiny microglobules of water characterized as mist, becomeentrained in and can be carried in the steam from the boiler. There is aprobability of the mist or globules containing impurities because thewater is just propelled out of the raw water in the boiler. Avoiding thesteam flashing problem just discussed removes one cause of mistproduction. It is important to make sure that no impure carryover waterin the form of mist or microglobules can ever reach the condenser andget into the distilled water storage tank. The invention disclosedherein solves this problem, too.

SUMMARY OF THE INVENTION

An objective of the invention is to provide for sensing a temperature onor in the boiler tray from which water is boiled and evaporated into theboiler steam chamber, which temperature is accurately correlated withthe need for infeed or replenishment of raw water even though the entireboiler tray has not become dry.

Another objective is to configure the boiler tray in such manner that itprovides a zone wherein temperature indicative of the need to add rawwater can be sensed while there is some boiling water remaining in thetray and where the zone is adequately, thermally isolated from that partof the tray in which the water is still boiling.

Another objective is to provide a boiler tray in which there is a recessthat always retains some residual boiling water so that when there is aninfeed of raw replenishment water the latter is discharged into theboiler tray on a surface that is not so hot that the raw water mightflash violently into steam. This objective is achieved by reason ofproviding a boiler tray whose interior bottom is formed in amultiplicity of steps or levels, so that water may be completelyevaporated from one or two of the higher level steps and yet have somewater remaining in the recess created by the lowest level step wheninfeed of replenishment of raw water begins.

Another feature of the improved distiller design disclosed herein is tocompel the steam that is discharged from the boiler to pass through acondensate separator or demister wherein water is separated from thesteam before the steam leaves for the condenser and to provide forautomatically drawing the condensate collected in the demister back intothe boiler tray under the influence of negative pressure created in theboiler chamber when cold raw water is injected into it. The demisterfeatures having spaced apart pin electrodes presented interiorly of it.The voltage drop across the pins is continuously monitored. If somethinghappens that results in the demister chamber filling with condensate oroverflow water, a voltage change is detected between electrode pins anda microprocessor based controller responds to the corresponding signalby shutting down the distiller completely.

The distiller disclosed herein also features carrying the boiler tray ina carriage that is detachably connected to the distiller housing doorsuch that by closing the door, the carriage and tray are advanced intothe housing for the leading end of the carriage to encounter a ramp. Theramp forces the carriage and tray in it to rise so that the tray effectsa sealed connection with a cover or dome that is fixed in the distillerhousing, thereby developing an enclosed boiler steam chamber. Thisfeature is known per se as illustrated in the previously cited patentsof the assignee hereof. However, the boiler tray for the distillerdisclosed herein is preferably an aluminum or an aluminum alloy castingwhich has the heater element attached to its exterior bottom with twoelectrical connector prongs extending from the tray. A downwardly biasedmovable electrical connector is positioned in the distiller housing forsupplying electric power to the heater element. When the boiler tray isadvanced into the housing as explained, the heater element prongs firstbecome inserted in the movable connector when the carriage and boilertray are still not lifted by the ramp. Then, as the leading end of theboiler tray is advanced further onto the ramp, and is lifted, themovable connector is also lifted and the prongs are plugged in soundlyto make a good electrical connection. The trailing end of the tray islifted correspondingly with the lift of the leading end by the ramp as aresult of the trailing end being connected to the door so when the doorcloses, the trailing end rises.

According to the invention, the boiler tray has an interior bottom inwhich there is a plurality of levels or steps, three steps in thepreferred embodiment, such as a succession of highest, intermediate andlowest level steps. Thus, water varies in depth from the least depthabove the highest level step to the greatest depth above the lowestlevel step. A valve is controllable to initiate and terminate infeed ofraw replenishment water to the boiler tray within a pre-set timeinterval measured by the microprocessor based controller. A probecontaining a temperature sensor is carried by the electrical connectormentioned in the preceding paragraph. Concurrently to its making of theelectric power connection to the prongs of the heater element, the probeon the connector is also inserted in the tray in acomplementarily-shaped hole such that the sensor is positioned forsensing the temperature primarily of the highest step surface in thetray bottom. Eventually, enough water is evaporated from the highestlevel step for that step to become dry. This is followed by theintermediate level step becoming dry. According to the invention, wateris still boiling in the recess defined by the sidewalls of the tray andthe lowest level step continues to boil at 100° C. and yield steam.Because the dry steps get hotter with time, the controller receives asignal that is representative of an increasingly higher temperature fromthe sensor in the probe. When this signal reaches a pre-determinedvalue, the controller responds by opening the raw water infeed valve andcool raw water flows into the boiler tray. The raw water can be directedonto the dry intermediate step in the tray bottom since that surfacewill be only slightly higher than the boiling temperature of waterbecause it is in heat conductive relationship with the lowest stepwherein water is still boiling and tending to keep the temperature ofthe intermediate step close to the boiling point of water. On the otherhand, because of the remoteness of the highest level step from theboiling water, that step increases in temperature more than theintermediate step so it reflects that the highest and intermediate stepsor levels are dry and that infeed of water is called for. Thereplenishing infeed water is metered for a measured time interval thatis sufficient for raw water to cover the intermediate and highest levelsteps in the bottom of the boiler tray before the raw water infeedsolenoid controlled valve is closed. Because of the intermediate stepbeing close to the temperature of boiling water when infeed ofreplenishment water begins, the infeed water does not flash into steambut is converted into steam after a slight delay during which all of thewater in the tray begins to boil.

How the foregoing and other specific objectives and features of theinvention are implemented will be evident in the ensuing more detaileddescription of a preferred embodiment of the invention which will now beset forth in reference to the drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the improved water distiller as itappears when ready for installation in the owner's kitchen cabinetry;

FIG. 2 is an exploded view of the distiller;

FIG. 3 is a perspective view of a carrier member for the water boilertray used in the distiller, the tray having been omitted;

FIG. 4 is an end elevational view of the boiler tray carrier as viewedin the direction of the arrows 4--4 in. FIG. 3;

FIG. 5 is a top plan view, that is, an inside view of the electricallyheated boiler tray that is used in the distiller to convert water tosteam;

FIG. 6 is a bottom plan view of the boiler tray;

FIG. 7 is a right side elevational view of the boiler tray depicted inFIG. 6;

FIG. 8 is a sectional view of the boiler tray looking through a verticalplane in the direction of the arrows 8--8 in FIG. 6, the tray standingin its upright water holding position rather than appearing inverted asin FIG. 3 and the electric heater element associated with the tray beingomitted;

FIG. 9 is a vertical sectional view of the boiler tray, the boilercarrier, the boiler cover member, the tube manifold and some other partsof the distiller;

FIG. 10 is a top plan view of the steam chamber showing the boiler covermember, the tube manifold, the support shroud and the demister of thedistiller;

FIG. 11 is a vertical section through a portion of the boiler covermember and tube manifold for illustrating how the raw infeed waterdischarges into the boiler tray;

FIG. 12 is a vertical sectional view through a portion of the boilercover member and tube manifold for illustrating how condensate isreturned from the demister to the boiler tray; and

FIG. 13 is a simplified diagram of the controller.

DESCRIPTION OF A PREFERRED EMBODIMENT

Attention is invited to FIG. 1 which is a perspective view of theimproved distiller ready for installation in a home for supplyingpurified potable water. The distiller is comprised of a cabinet orhousing 10 to which a front-end housing section 11 is attached. Housingsection 11 has on its face an array of push-button switches, a doorlatch actuator button, and distiller status indicator lights which arecollectively identified by the numeral 12. The housing section 11 alsohas a door 13 that pivots about a horizontal axis to provide forinserting into the housing and for withdrawing a steam boiler evaporatortray from the housing for inspection and cleaning. The tray is notvisible in FIG. 1 but its structure and function will be exhibited anddescribed in detail later. The front section 11 also has a grill 14 fordischarging from the housing cooling air after it has passed over asteam condenser in the housing under the influence of a motor-drivenfan, neither of which are visible in FIG. 1. A tank 15 in which thepurified distilled water is stored is releasably mounted to the basemember which is concealed in the housing in FIG. 1.

Major parts of the distiller not thus far identified are identified inreference to the FIG. 2 exploded view. The horizontally disposed basemember of the distiller is identified generally by the numeral 20. Thepreviously mentioned purified water storage tank 15 is secured to a basemember 20 with thumbscrews 21 and a gasket 22 is interposed between thetank and base member. A sensor 23 mounts in a base hole 24 and extendsinto tank 15 for providing a signal or signals indicative of the waterlevel in the storage tank. A motor and pump unit 25 is mounted to thebase 20 by way of a multiple purpose bracket 26. The pump has an intaketube 27 for drawing water from storage tank 15 and an output tube 28 fordelivering water to a faucet, not shown. Water is conducted to thefaucet through fittings and a pressure sensor which are shown as fiveparts that are collectively designated by the number 29. Thesecomponents may be seen in any of the three patents cited earlier.

A microprocessor based controller and intelligence center 30 for thedistiller is symbolized by the circuit board 31 which has themicroprocessor, integrated circuits and other electronic componentsmounted to it. Certain circuits and control functions governed bycontroller 30 which are pertinent to the invention disclosed herein willbe discussed later as required. The controller 30 circuit board 31 isretained in slotted posts 32 projecting upwardly from distiller basemember 20.

Continuing with mentioning the principal components of the distiller,FIG. 2 also shows a conventional steam condenser 35 comprised of atubular coil and fins for condensing steam generated in the distiller towater.

Coolant air is drawn through condenser 35 under the influence of a fan36 driven by an electric motor 37. Before the coolant air stream enterscondenser 35, the air passes through a filter 38. The fan 36 and themotor 37 combination is mounted to an apertured plate 39 which mounts tobase member 20. Brackets such as the one marked 40 are provided formounting members such as electrical components 41 and 42. The electricpower input supply cord to the distiller and its attachment plug isdesignated generally by the numeral 43.

The components of the distiller thus far described are also present inthe three patents of the assignee mentioned earlier in thespecification.

The pre-existing distiller design employs a raw water boiler tray forproducing steam and for accumulating biological contaminants and mineralsediment extracted from the water. The predecessor designs also mountthe boiler tray in a carrier that facilitates inserting the tray intothe distiller housing and withdrawing it from the housing. The newboiler tray is indicated generally by the numeral 45 in FIG. 2 and thenew carrier is designated generally by the numeral 46. The distinctivestructural and functional features of the new tray 45 and carrier 46will be discussed later.

As in the previously cited patents, there is shown in FIG. 2 a supportframe or shroud 50 in which a boiler tray cover member, generallydesignated by the numeral 51 is mounted integrally. The cover member 51is, according to the invention, integrated with a demister chamber 52which has novel structural and functional features that will bedescribed in detail later. Boiler cover member 51 is fixedly mounted ondistiller base member 20 through the agency of shroud 50 as was the casein the cited earlier patented designs. When carrier 46 is inserted intodistiller housing 10 with the boiler tray 45 mounted in the carrier 46and the carrier is sliding along base member 20, the carrier and boilertray 45 become elevated so that the upper rim of the tray makes a sealedconnection with the bottom of the downwardly concave cover member 51.Thus, cover member 51 and boiler tray 45 cooperate to define an enclosedsteam chamber which will be discussed in more detail later.

FIG. 2 also depicts a newly designed tube manifold that is designatedgenerally by the numeral 55. An enlarged view of the manifold 55 ispresented in FIG. 10. Tube manifold 55 has a portion 56 that interfacessealingly with the top of the boiler cover member 51 and is securedthereon with screws such as the one marked 53. The manifold also has aportion that is sealingly interfaced with the demister chamber 52. Tube58 on the manifold conducts steam from the steam chamber or boiler tothe demister chamber 52 which separates particulate water globules ormist that is carried over with the steam and which must be preventedfrom going to the condenser since the mist may contain solids. Thesteam, after having the mist removed, is discharged from demister 52through a tube 60 that is connected by means of a hose 601 to the inlet602 of condenser 35. Another tube 59 on the manifold is for returningcondensate collected in the demister back into the steam chamber forreprocessing. This process will be discussed in detail later. The thirdtube 61 on the tube manifold 55 is for admitting unprocessed raw waterto the steam chamber that is defined by the cover member 51 and boilertray 45 which is sealingly engaged with the cover member. Raw waterinfeed tube 61 on tube manifold 55 connects by way of a tube 62 to theoutlet of a flow restricter 63. Flow restricter 63 has a raw waterinflow from the outlet of an electrically controlled raw water infeedsolenoid valve 64 whose inlet connects to an elbow 65. The elbowconnects to a pipe, not shown, which connects to the water distributionsystem in the building.

In FIG. 2, a movable electrical connector assembly 66 is depicted abovethe distiller base 20. This connector supplies electric power forheating the boiler tray 45. A probe 128 extends from the connector andcontains a temperature responsive sensor, not visible, as will beelaborated later.

The features of the improved boiler tray 45 will now be described indetail in reference to FIGS. 5-8 primarily. The tray 45 is preferably acast aluminum member. In the FIG. 5 plan view, one may see that theboiler tray 45 is comprised of a generally rectangular rim 66 whichencompasses a recess for containing water that is to be converted tosteam. The recess defined by rim 66 is evident from inspection of theFIG. 8 vertical section of the boiler tray 45. The rim has a perimetralgroove 66 which augments the sealing effectiveness of a gasket 68 thatis shown in FIG. 9 where the boiler tray 45 is shown interfaced with thecover member or dome 51 that defines the steam chamber 105 inconjunction with the boiler tray 45. The interior bottom of boiler tray45 as shown in FIGS. 5 and 8 is formed with a plurality of levels orsteps, particularly, three steps in the illustrated embodiment. Thehighest level step is marked 69. This step has a riser 70 which connectsthe highest level step 69 with the next lower or intermediate level step71 in the boiler tray bottom. Step 71 has a riser 72 which connectsintermediate step 71 with the lowest level step 73 in the boiler traybottom. As one may observe in FIG. 5, the lowest level step 73constitutes the bottom of a U-shaped recess or sump which can contain asubstantial quantity of water. It should be evident from inspection ofFIG. 8 that if boiler tray 45 were about half full of water, the depthof water above the highest level step 69 would be less than the depth ofwater over intermediate step 71. The depth of water over the lowestlevel step would be greater than the depth of water over intermediatestep 71 and over the highest level step 69. The interior of the boilertray 45 including the three steps is coated with a non-stick material.Polytetrafluoroethylene is an example. The non-stick coating acts as arelease layer for the residual sediment and mineral that remains afterthe raw water is boiled out of the boiler tray. It is important to notethat if the boiler tray 45 were filled with water in the first instanceand then heated continuously to convert the water to steam withoutadding water, the highest level bottom step 69 would become dry firstand the intermediate level step 71 would become dry next. Even thoughthe highest level step 69 and the intermediate level step 71 would havegone dry, boiling water could still remain in the recess that has thelowest level step 73. The three levels or steps in the bottom of theboiler tray are utilized, in accordance with the invention, toparticipate in overcoming the problem of raw infeed water flashing intosteam with explosive force and replenishment raw water is fed into theboiler tray as mentioned earlier.

The top plan view of the boiler tray 45 in FIG. 5 shows in dashed linesthe U-shaped configuration of the electric heater element 74 which isenergized when required to provide the heat for evaporating water fromthe boiler tray and converting it to steam. Heater element 74 terminatesin two conductive connector prongs 75. The FIG. 6 bottom view of boilertray 45 shows that the heater element 74 is in intimate heat exchangerelationship with the exterior boiler tray bottom and the element 74resides in a correspondingly shaped groove. In FIG. 8, where the heaterelement 74 is not yet installed in the boiler tray, one may see an emptygroove 77 of a size for receiving a heater element. A lip 78 forms oneside of the groove. After the heater element is installed in groove 77,lip 78 is crimped to hold the heater element in place.

One may see in FIGS. 5-8 that boiler tray 45 has a bore 79 underlyingthe highest level step 69 in the boiler tray 45 bottom. As will bediscussed in more detail later, bore 79 is provided for receiving probe128 on connector 66 which was discussed earlier in .reference to FIG. 2.As mentioned earlier, there is a temperature sensor, not visible, inprobe 128 although the probe is shown in FIG. 9. The sensor, notvisible, is involved in determining the proper time for opening the rawwater infeed valve 64 shown in FIG. 2 for adding water to the boilertray 45 during distiller operation without having the infeed raw waterflash into steam with explosive force.

The carrier 46 for the boiler tray 45 is shown isolated from thedistiller in FIGS. 3 and 4. Carrier 46 may be, and preferably is, moldedfrom a low thermal conductivity plastic material. The carrier has afront or trailing end wall 85 and a rear or leading end wall 86 plusside walls 87 and 88. A bottom recess 89 can provide room for a thermalinsulating mat, not shown, under the bottom of the electrically heatedboiler tray 45. The rear or leading end wall 86 of the carrier has anopening 90 to which the connector prongs 75 and 76 of the boiler trayheater element can project. The boiler tray 45 is stabilized withincarrier 46 by resting on ribs such as the one marked 91. On the outsideof the rear wall 86 of the tray carrier 46 and formed integrally withthe carrier body is a guide member 92 that has a flat top 95 which canbe used as a handle for handling the carrier when it is retracted fromthe distiller housing. Handle member 95 spans between two runners 93 and94 which are involved in the process of effecting a connection betweenconnector body 66 with probe 128 and the two prongs 75 and 76 whichextend from the-boiler tray heater element 74. The runners 93 and 94have a special curved configuration as can be seen in FIG. 9 where onerunner, 93, is visible. Involvement of the runners in making theelectrical connection between movable or floating connector 66 and theelectrical heater element will be described shortly hereinafter.

As shown in FIGS. 3 and 4, the front or trailing end of carrier 46 isprovided with longitudinally extending webs 99 and 100 which are bridgedand stiffened by a handle member 101. The webs and curved handle member101 are molded integrally with the front or trailing end of the carrier.Pins 102 and 103 extend laterally outwardly from the respective webs 99and 100. Pins 102 and 103 participate in the function of inserting thecarrier 46 into the distiller housing and also in lifting the rear endof the carrier 46 as the front end is lifted, when the carrier isinserted in the distiller housing, by means of the outer surface of theleading end wall 86 of the carrier riding on some ramps 112 which arevisible particularly well in FIG. 2.

Attention is now invited to FIG. 9 which shows the boiler tray 45elevated into sealed relationship with the fixedly mounted steam chambercover or dome 51 for creating a steam collection chamber 105. A gasket68 is interposed between the boiler tray 45 and chamber cover 51. Tray45 is in carrier 46 and is securely pressed upwardly to effect a goodseal. Provision is made for elevating the carrier 46 in a level state asit advances into the distiller housing. Front door 13 of housing section11 referred to in reference to FIG. 2 is involved with insertion of anelevation of boiler tray 45 into sealing relationship with steam chambercover 51. Front door 13 on housing section 11 pivots to open and closedposition on laterally extending pins one of which, 110, is visible inFIG. 9. As explained in reference to FIG. 3, tray carrier 46 has pins102 and 103 extending laterally in opposite directions at the front ortrailing end of the carrier 46. Pin 102 is visible in FIG. 9 where it isshown residing in a notch or slot 111 in door 13. Pin 103 on a carrierwould also extend into a slot similar 111, but this pin is not visiblebecause it is taken from the forefront in the FIG. 9 sectional view.Door 13 is presently shown in FIG. 9 in its closed position as a resultof which the front end of carrier tray 46 is forced upwardly to causecompression of gasket 68 while the leading end of tray 45 is supportedon a flat surface 117 of a post 113 after the tray has been caused torise when it is being inserted along the ramp surface 118. It should beapparent in FIG. 9 that if the door were open by swinging itcounter-clockwise to about 90° degrees, the engagement of pins 102 and103 in door notches 111 would result in carrier 46 and boiler tray 45thereon being partially withdrawn from the distiller housing and beingaccessible for complete withdrawal for maintenance of the tray such asfor removal of sediment.

In FIG. 9, the leading or rear end of the carrier 46 exhibits a largeradius curvature 115. The curved portion is confluent with a straightbottom face portion 116 which bears on the horizontal top edge 117 ofthe ramp members 112 and 113. Only ramp member 113 is visible in FIG. 9,but the other ramp member 112 can be seen in FIG. 2. If, in FIG. 9, thedoor 13 were swung counter-clockwise, the rear end of the carrier whichexhibits a large radius curved portion 115 would descend along the rampsurface 118 due to the carrier being drawn outwardly from the housing bya certain amount as a result of the swinging of the door. The curvedportion 115 of the carrier 46 is confluent with a straight bottom faceportion 116 which bears on the horizontal top edge 117 of the rampmembers 112 and 113. Only ramp member 113 is visible in FIG. 9, but-theother member 112 can be seen in FIG. 2. If the front door 13 is swungcounter-clockwise on pivot pin 110 and its counterpart, the lateral pins102 and 103 on the boiler tray being engaged in slots 111 on the door,will travel through an arc which has a vector component that causes thefront end of the carrier to descend and a vector component that causesthe front end of the carrier to begin extending from the distillerhousing. This provides access to the carrier 46 handle 101 forcompletely withdrawing the carrier 46 and boiler tray 45 therein out ofthe distiller housing. While the door is swinging counter-clockwise andmaintaining the trailing or front end of the carrier at a predeterminedlevel, the curved cam surface 115 on the carrier 46 rides onto theangulated ramp surface 118 which guides the rear end of the carrier inits descent. The angle of the ramp surface 118 at the rear end of thecarrier and the radius of the arc to which the lateral pins 102 and 103swing are correlated such that the carrier 46 and tray 45 are kept levelduring carrier and tray retraction, so if there is water in the boilertray 45, there will be no spill. According to the invention, the door 13is secured in locked position for a period of time that makes certainthe temperature of the carrier and tray is low enough to handle withbare hands without being burned.

After the sediment and mineral deposits have been brushed out of theboiler tray 45, the tray can be inserted in the carrier, and the carriercan be installed in the cabinet again for resumption of the distillingprocess. Restoring carrier 46 with boiler tray 45 in it into thedistiller housing requires that the front door 13 be open far enough forinserting the carrier and boiler tray in the housing 10. While the dooris open, carrier pins 102 and 103 are caused to register in the doorslots 111. At this time the curved leading end portion 115 of thecarrier is proximate to the 113, but the carrier has not begun itsascent. Then, by closing the door 13 to its vertical position as itappears in FIG. 9, the front end or trailing end of the carrier islifted and urged inwardly by the door while the leading or rear end ofthe carrier portion 115 rides rearwardly and upwardly on the inclinedpart 118 of ramp member 113. The carrier 146 and the boiler tray staylevel while being elevated by the swinging door at one end and the rampat the other end, and the rim 65 of the boiler comes up squarely orlevel to compress gasket 68 and seal the boiler tray to the steamchamber cover member 51.

Observe in FIG. 9 that the carrier 46 has a depressed region 120. Thedepressed region 120 is also visible in FIG. 4 where it is showncentered with the carrier and as having a width less than the width ofthe carrier 46. The depressed region 120 constitutes a guide whichassures that the carrier will move along a straight pre-determined pathwhen the carrier is inserted into and withdrawn from the distiller. Asshown in FIG. 2, the distiller base 20 has tracks 121 which bound thesides of the depression guide for steering the carrier 46 straight intothe distiller housing.

When describing the carrier earlier in reference to FIGS. 3 and 4, theopening 90 at the rear end of the carrier was mentioned as were thelaterally separated webs or runners 93 and 94. The purpose of therunners will be expanded in reference to FIG. 9.

FIG. 9 shows the movable electrical connector and probe assembly 66which was depicted in FIG. 2. Connector 66 has laterally extending guidepins such as the one marked 125 in FIG. 9. Pin 125 presently resides inthe horizontal part 126 of a guide that curves into a vertical part 127.Thus, the connector 66 has vertical and horizontal components ofmovement. Biasing means such as a pair of springs, one of which 129, isvisible in FIG. 9 and is presently loaded in tension with the resultthat it tends to urge the connector 66 forwardly, that is, to the left,and downwardly. This movement is precluded by the heater elementconnector pins 75 and 76 being plugged into the connector 66 and thetemperature probe 128 being inserted in hole or socket 79 in the boilertray. As indicated earlier, the probe contains a temperature sensor, notvisible, that established under the highest level step 69 of the boilertray 45 bottom. The web or curved runner 130 the curved portion ofrunner or web 93 presently rests on the top 131 of the riser or supportmember 132. The other runner 94 would be similarly supported in theactual construction. When the tray carrier 46 and the boiler tray 45 areretracted by partial opening of the front door 13 of the distillerhousing as previously explained, runner 93 glides off support surface131 to allow the connector to descend under the force of spring 129 andthen stop. The connector stays in its lowermost stopped position afterthe heater connector pins 75 and 76 are withdrawn from connector 66 andthe boiler tray separates from probe 129 as the carrier is withdrawnfrom the distiller housing 10.

During the restoration of the carrier 46 and the tray 45 in it to thedistiller, the electrical connector prongs 75 and 76 on the heaterelement begin entry into connector 66 when the connector is in itslowermost position and at the time the temperature probe 128 beginsentry into the tray hole 79. The carrier 46 begins to rise in a levelstate as it is pushed into the housing 10 by closure of the door 13 dueto the reaction of the curved cam surface 115 on the carrier against theangular surface 118 on ramp 113. Concurrently, connector 66 rises andopposes the force of spring 129 and opposes the force of the inwardlymoving carrier 46 as well. By the time the boiler tray 45 seals againststeam chamber cover member 51, the boiler tray 45 and connector 66 arefully connected.

FIG. 10 shows in dashed lines a generally semi-circular baffle 140 inthe demister against which the steam discharging from tube 58 impingesfor the purpose of absorbing the kinetic energy of the microglobules ofwater so they are induced to separate from the steam and to collect inthe bottom of the demister chamber 52. Of course, the demister 52 issubstantially cooler than the steam chamber which also encourages theglobules or mist to drop out of suspension from the steam.

In FIG. 9, one may see that the steam and mist, if any, is conductedthrough a check valve 141 interposed between the steam chamber 105 andsteam outlet tube 58. The check valve is disclosed in the patents of theassignee cited earlier in this specification. The ball 142 in the checkvalve is presently seated which is the case when no steam pressure hasdeveloped in steam chamber 105. When steam pressure develops in chamber105 it lifts the ball 142 and steam passes the check valve and isconducted through tube 58 to demister 52. The steam passes through tothe check valve through the side opening 143 of a baffle 144 whichinhibits the passage of microglobules of water or mist that may rise inthe steam from boiler tray 45 due to vigorous boiling of the water inthe tray.

The steam strikes the baffle 140 in the demister as it is beingdischarged from tube 58. The water particles in the steam by collidingwith the baffle will drop down and flow to the lowest part of thedemister 52 chamber. According to the invention, condensate collected inthe demister is returned to the steam chamber 105 coincident with thetime that replenishment water is supplied to the boiler tray. For thispurpose, a vertical conduit 146 in the demister has its lower open end147 terminating in the lowest part of the demister where the condensatecollects. Vertical conduit 146 connects to horizontal tube 59 on thetube manifold as shown in FIGS. 10 and 12. In FIG. 12, it will beevident that tube 59 is terminated in the steam chamber 105 with a checkvalve 148. Check valve 148 permits flow of steam into chamber 105 butcloses securely under the influence of steam pressure in chamber 105 sosteam is limited to leaving chamber 105 only through the otherpreviously discussed check valve 141.

The circumstances under which condensate is withdrawn from demister 52and returned to boiler tray 45 are as follows. In operating cycle afteroperating cycle when most of the water is evaporated from the boilertray it must be replenished. At the time infeed of raw water isinitiated, steam chamber 105 contains steam at some pressure aboveatmospheric pressure. When solenoid water infeed valve 63 in FIG. 2opens, there is an infeed of cool raw water to steam chamber 105 whichcondenses the steam for a short interval, thereby causing chamber 105 toattain a negative pressure relative to the pressure existing withindemister 52. This negative pressure seats the ball in steam dischargecheck valve 142 so the suction due to negative pressure is not shortcircuited by steam outlet tube 55. However, the negative pressure in thesteam generator 105 allows check valve 148 to open so condensate drawnfrom demister 52 can flow into the steam chamber 105. Use of the secondcheck valve 148 in the condensate return tube 59 may be avoidable butuse thereof is preferable.

A short time after replenishing water is admitted to the boiler tray 45,positive steam pressure develops in the chamber 105, check valve 142opens and check valve 148 closes. Then the evaporation cycle continues.

The raw water infeed tube 60 on the tube manifold 55 is shown in FIG. 10and in FIG. 2. It has been mentioned previously that infeed of raw wateris regulated insofar as flow rate concerned by a flow restrictor 62 andis started and stopped by electrically operated valve 63 under thecontrol of the microprocessor based controller 30. Overflow protectionis provided in the demister and steam chamber by the use of preferablystainless steel electrode pins 150 and 151 which are embedded inelectrically non-conducting plastic bosses in the demister cover asshown in FIG. 9. Tips 154 and 155 of electrode pins 150 and 151 arerecessed so they will only be wetted if water rises in the demister 52sufficiently for the demister to fill. Because the tips are set back orrecessed in the bosses, the tips will only be wetted if water rises upto the full level in the demister 52. A resistor 156 is connectedbetween electrode pins 150 and 151.

The voltage drop between the two screws 150 and 151 is measuredcontinuously when steam is passing through the demister 52. A certainvoltage drop is sensed between the electrode pins. If the demistershould fill with water the gap between the electrode pins 150 and 151would be bridged by carryover water so the voltage drop changes. Waterthen constitutes one conductive path between the electrode pins andresistor 156 constitutes the other path. Water and the resistor 156comprise a parallel circuit whose total resistance is necessarily lessthan the resistance of the lowest resistance path. The resulting voltagedrop change is detected by the microprocessor in controller 30 whichresponds by issuing a signal to attract the attention of the user of thedistiller. The demister 52 might fill with carryover water if the ballin check valve 148 sticks on its seat, or if the steam chamber valve 142fails to close so there is no vacuum developed in the steam chamber whencool raw water is fed in.

The raw water infeed tube 60 on tube manifold 56 has been identifiedpreviously in reference to FIGS. 2 and 10. How infeed tube 60 ispositioned is exhibited in FIG. 11. The arrow indicates flow directionof raw water into fragmentarily shown steam chamber.

The phenomena incidental to use of the three level or three step boilertray will now be discussed. Assume that the distiller has not been usedbefore so that boiler tray 45 is empty and that raw infeed water isavailable. The electric power is turned on and nothing happens until thetemperature sensor in probe 79 ultimately detects that the boiler tray45 has been preheated to about 120° C. When this condition is met,controller 30 causes solenoid controlled water infeed valve 64 to openand deliver water through flow restrictor 63 to boiler tray 45. Theheater element is turned off concurrently with opening of infeed valve64. In the preferred embodiment of the invention, raw infeed water isfed to the boiler tray during a predetermined time interval since flowrestrictor 63 governs the flow rate. Time and flow rate are related suchthat a definite known quantity of water is supplied to the multiplelevel boiler tray 45. By way of example, and not limitation, water isfed to the boiler tray at the rate of 15 ml per second in the actualmodel of the distiller. If the time interval is 7 seconds, for example,about 105 ml will enter the boiler tray. Means are provided for drivingthe heater element at various power levels, up to 500 watts for example.When the fill cycle ends, the distiller goes into the 100% power levelmode and starts boiling the water to make steam which is fed through theinlet 602 of the condenser 35. As boiling proceeds, the water level inboiler tray 45 drops and the first thing that happens is that thehighest or first level step 69 in the boiler tray becomes dry. Water,however, continues to boil on the intermediate level or step 71 and onthe lowest level or step 73 as those levels are identified in the boilertray depicted in FIG. 8. As long as there is water on the second level71, the highest or first level or step 69 and the second or intermediatelevel step 71 stay at about 100° C. because of the cooling effect on thetray of water boiling at substantially atmospheric pressure on thesecond level 71 as well as on the third step or level 73. As steamproduction continues the intermediate step 71 eventually becomes devoidof water and its temperature starts to rise. Water continues to boil inthe recessed bottom or the lowest level step 73, but the water at thatlevel is sufficiently isolated thermally from the dry intermediate stepand the first or highest step in the bottom of the tray so that thetemperature of the highest level step begins to rise rather rapidly whendry. However, the residual water in the lowest or third level 73, eventhough it is boiling, keeps the second 71 and first 69 levels or stepsat a little more than 100° C. The temperature sensor in probe 128, whichresides under the highest level step 69 in the boiler tray, senses thissmall increase over 100° C. and signals controller 30 to open the rawwater infeed valve 64 and to turn the heater off. As explained earlier,water is then fed into the boiler tray 45 for a pre-determined timeinterval after which the controller causes the valve 64 to close. Thedischarge nozzle 160 (FIG. 11) of the water infeed tube 60 is sopositioned that the water is discharged onto the intermediate level step71 on the boiler tray 45. One reason for this is that it is desirable toequalize the temperature throughout the boiler tray and, essentially, tocool the highest level 69 in the tray so the temperature sensor in probe128 detects a temperature corresponding with the boiling temperature ofwater. When the raw infeed water lands on intermediate level step 71,there is a momentary pressure surge or spike that is milliseconds long.The duration of the spike and, hence, the energy involved is relativelysmall such that the accompanying surge in pressure within the steamchamber 105 can be relieved through the check valve 141 to thecondenser. Since water is flowing into the boiler tray 45 at this timethe steam prevailing in boiler chamber 105 condenses such that for aperiod of at least 2 and probably 5 seconds a negative pressure developsinside of the chamber 105. Development of negative pressure does notbegin until after the heater element is turned off. This seats the ball142 of check valve 141. At the end of the 2-5 second negative pressureinterval, incoming water absorbs heat from the metal mass constitutingthe boiler tray 45 which acts as a massive heat sink. It is better toabsorb this heat for a useful purpose than to let it be propagated outof the boiler tray and carrier 46. During the seconds long interval whennegative pressure exists in the steam chamber 105, the negative pressureis propagated to the interior of demister 52 such that the separatedcondensate is drawn by the negative pressure through vertical conduit146 and horizontal tube 59 and then through check valve 148 so thecondensate that has been accumulated in the demister is returned to theboiler tray 45. The check valve 148, depicted in FIG. 12, is sopositioned that the water withdrawn from the demister 52 is alsodirected onto the intermediate level step 71 in the boiler tray bottom.Thus, flashing of the demister return water into steam is furtherprevented from developing a pressure spike of significant duration.

The heater element is not turned on again until the boiler traytemperature has dropped to about 105° C. Then, the boiler tray continuesin its steam producing mode until infeed water is called for again as aresult of levels 69 and 71 having had all water evaporated from them.

The circuitry associated with microprocessor based controller 30 can bedevised by an experienced designer. The circuit shown in U.S. Pat. No.5,188,710 is suggestive. This patent is incorporated herein byreference. The functions of main interest, insofar as the inventiondisclosed herein is concerned are shown in the FIG. 13 block diagramhereof. There is a door switch signal input to the controller. If thehousing door 133 is open the controller deactivates the system. The dooris latched closed until boiler tray 45 is cool enough to handle. Thereis a boiler tray temperature signal input to controller 30 which hasbeen discussed in detail earlier. The voltage drop across demisterelectrodes 154, 144 is another input to the controller. A voltage changemay signal a high water level which can result in an audible or visiblesignal that indicates the existence of this condition. Some of the otherinput and output signals incidental to distiller functions are mentionedin U.S. Pat. No. 5,188,710.

It is claimed:
 1. A water distiller comprising:a boiler chamber havingan inlet for raw water and an outlet for steam, means for heating theboiler chamber to boil water and thereby produce steam in the boilerchamber at a pressure above atmospheric pressure with mist in the steam,a demister comprised of a demister chamber having an inlet for steamentraining mist from said boiler chamber and having an outlet for saidsteam from which the mist is separated, and remains in the demisterchamber as condensate, a first check valve having an inlet coupled tothe boiler chamber for receiving from said boiler chamber steam aboveatmospheric pressure that entrains mist produced in the boiler chamberand having an outlet coupled to said inlet of the demister chamber, thefirst check valve being operative to open in response to steam underpressure, a tube having an inlet coupled to the demister chamber forreceiving said condensate separated from the steam in the demisterchamber and having an outlet coupled to the boiler chamber, a secondcheck valve in series with the tube, said second check valve beingoperative to close in response to said steam above atmospheric pressureexisting in the boiler chamber and to open in response to vacuumexisting in the boiler chamber, a temperature sensor operative toproduce a signal indicative of the need for raw water replenishment insaid boiler and a controller responsive to said signal by controllingsaid infeed valve to open to admit raw water to said boiler chamber andto close, means for creating vacuum in the boiling chamber comprisingraw water infeed valve having an inlet for raw water and an outletcoupled to the boiler chamber inlet for raw water, wherein opening ofsaid water infeed valve when said steam at above atmospheric pressure ispresent in the boiler chamber to admit water that is cooler than steaminto the boiler chamber causes said steam to condense in the boilerchamber to thereby create the vacuum in the boiler chamber such that thefirst check valve closes under influence of said vacuum and the secondcheck valve opens under the influence of said vacuum to effect drawingcondensate from the demister chamber through the tube into the boilerchamber under the influence of the vacuum.
 2. The distiller according toclaim 1 wherein said demister chamber has a bottom and a tubular memberhaving a lower condensate input end opening proximate to the bottom andan upper end connected in series with said tube.
 3. The distilleraccording to claim 1 or 2 including a baffle member in said demisterchamber, the baffle member having a concave surface, and said inlet tosaid chamber for steam entraining mist from said boiler chamber isarranged to direct the steam against the concave surface of the bafflemember.
 4. The distiller according to claim 3 wherein said concavesurface is substantially semi-circular.
 5. A water distillercomprising:a boiler chamber having an inlet for raw water and an outletfor steam, means for heating the boiler chamber to boil water andthereby produce steam under pressure, a demistar comprised of a demisterchamber having an inlet for steam from said boiler chamber and having anoutlet for steam, a first check valve having an inlet coupled to theboiler chamber for receiving steam produced in the boiler chamber andhaving an outlet coupled to said inlet of the demister chamber, saidfirst check valve opening in response to steam pressure in the boilerchamber, a second check valve having an inlet coupled to the demisterchamber for receiving condensate separated from the steam in thedemister chamber and having an outlet coupled to the boiler chamber,said second check valve closing in response to steam pressure in theboiler chamber, means for creating vacuum in the boiler chambercomprising raw water infeed valve having an inlet for raw water and anoutlet coupled to the boiler chamber inlet for raw water, whereinopening of said water infeed valve when steam is present in the boilerchamber to admit water that is cooler than steam into the boiler chambercauses steam to condense in the boiler chamber to thereby create thevacuum in the boiler chamber such that said first check valve closes andsaid second check valve opens in response to said vacuum to effectdrawing condensate from the demister chamber into the boiler chamberunder the influence of the vacuum, a temperature sensor operative toproduce a signal indicative of the need for raw water replenishment insaid boiler and a controller responsive to said signal by controllingsaid infeed valve to open to admit raw water to said boiler chamber andto close, at least two electrodes arranged with a gap between them inthe demister chamber, said controller including means for detecting thevoltage drop between said electrodes when steam is passing through saiddemister chamber and said controller further responding to a change inthe voltage drop due to water rising in said demister chambersufficiently to bridge the gap between said electrodes by issuing asignal.
 6. The distiller according to claim 5 wherein said demisterchamber has a bottom and said electrodes are mounted in said demisterchamber in a member positioned above the bottom comprised of insulatingmaterial with a surface on each electrode set back in a downwardlyopening recess in said material to assure that only a water rising to alevel in the demister chamber sufficiently high to enter the recess canbridge the gap between electrodes.
 7. A water distiller comprising:aboiler chamber having an inlet for raw water, means for heating theboiler chamber to generate steam at above the atmospheric pressure inthe boiler chamber, a demister comprised of a demister chamber having aninlet for receiving from the boiler chamber steam that contains mist andhaving an outlet for steam from which the mist is removed as condensatethat accumulates in the demister chamber, a first check valve having aninlet coupled to the boiler chamber and an outlet coupled to the inletof the demister chamber, the check valve opens in response to thepressure of steam at above atmospheric pressure in the boiler chamberfor passing steam that entrains mist to the inlet of the demisterchamber and for closing in response to occurrence of a vacuum in thesteam chamber, a second check valve having an inlet in communicationwith condensate in the demister chamber and an outlet coupled to saidsteam chamber, the second check valve closes under the influence ofsteam above atmospheric pressure in the boiler chamber, means forcreating vacuum in the boiling chamber comprising raw water infeed valvehaving an inlet for raw water and an outlet coupled to the boilerchamber inlet for raw water, wherein opening of said raw water infeedvalve when steam at above atmospheric pressure exists in said boilerchamber causing the steam to condense and create the vacuum in theboiler chamber that causes the first check valve to close and causes thesecond check valve to open to draw the condensate from the demister intothe boiler chamber.
 8. A method of distilling water comprising the stepsof:heating raw water in a boiler chamber to produce steam and mist atabove atmospheric pressure therein, conducting steam entraining mist toa demister chamber through a steam exiting check valve that opens inresponse to steam pressure in the boiler chamber, converting the mist tocondensate in the demister chamber, separating steam from thecondensate, conducting steam separated from condensate in the demisterchamber to a condenser for producing distilled water while condensateaccumulates in the demister chamber, admitting raw water into saidboiler chamber periodically for replenishing water converted to steamand for condensing the steam in the boiler chamber to create a vacuumtherein, such that said steam exiting check valve closes, positioning aconduit with an inlet exposed to the condensate in the demister chamberand an outlet in communication with the boiler chamber with a checkvalve in the conduit opening in response to vacuum existing in theboiler chamber to draw condensate in the demister chamber into theboiler chamber.